Conveyor assembly with offset bearings

ABSTRACT

A noseroller assembly for transitioning a conveyor belt at an end of a carryway comprises offset bearings for guiding a conveyor belt. A first set of bearings protrudes slightly from the end of the noseroller substrate to guide the conveyor belt around the noseroller and a second set of bearings in recessed from the end of the noseroller substrate to prevent wear.

RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication No. 62/238,926, filed Oct. 8, 2015 and entitled “ConveyorAssembly with Offset Bearings”, the contents of which are hereinincorporated by reference.

FIELD OF THE INVENTION

The present application relates to power-driven conveyors. Moreparticular, the present invention relates to a noseroller assembly fortransitioning a conveyor belt between a carryway and a returnway.

BACKGROUND OF THE INVENTION

Conveyor bells are widely used in various industries to convey products.Endless conveyor belts are generally trained around reversing elements,such as sprockets or noserollers, to form an endless circuit having acarryway and returnway. Modular plastic conveyor belts are constructedof a series of rows of side-by-side belt modules. Hinge eyes alongopposite ends of each row interleave with hinge eyes of consecutiverows. A hinge rod inserted in the interleaved hinge eyes connects therows together at hinge joints into an endless conveyor belt loop.

Certain modular plastic conveyor belts have difficulty going aroundnoserollers or other reversing elements. The transition from thecarryway to the returnway often causes vibrations and jolting in themodules, creating instability in the conveying surface. In addition,excessive wear on conveyor modules, caused by rubbing against thenoseroller right before a transition point, can be a problem.

SUMMARY OF THE INVENTION

A noseroller assembly for a conveyor comprises bearings that are offsetfrom each other. A first set of bearings protrudes slightly from the endof the noseroller substrate to guide the conveyor belt around thenoseroller and a second set of bearings is recessed from the front endof the noseroller substrate to prevent wear.

According to one aspect, a noseroller assembly for transitioning aconveyor belt at an end of a carryway comprises a substrate having arounded front edge, a first set of bearings rotatably mounted to thebase and aligned along a first axis, and a second set of bearingsrotatably mounted to the base and aligned along a second axis spacedfrom the first axis.

According to another aspect, a noseroller assembly comprises a substratehaving a rounded front edge, a first opening in the substrate forrotatably mounting a bearing and a first bearing mounted in the firstopening such that the front surface of the first bearing is recessedfrom the rounded front edge.

According to another aspect, a noseroller assembly for a conveyor beltcomprises a first bearing module having an upper surface, a first sideedge, a second side edge, a rounded front edge, a rear edge, a bottomand an opening in the upper surface for receiving a bearing, a firstbearing mounted in the opening of the first bearing module, a secondbearing module adjacent the first bearing module having an uppersurface, a first side edge adjacent the second side edge of the firstbearing module, a second side edge, a rounded front edge, a rear edge, abottom and an opening in the upper surface for receiving a bearing, asecond bearing mounted in the opening of the second module and aconnector for connecting the first bearing module and the second bearingmodule so that the rounded front edges align with each other.

According to another aspect, a conveyor belt module comprises a modulebody extending from a top surface to a bottom surface, laterally from afirst side edge to a second side edge and longitudinally from a firstend to a second end, a plurality of spaced-apart hinge elementsextending from the first end and the second end and a plurality ofbearing pockets formed in the bottom surface for accommodating anoseroller assembly having bearings.

BRIEF DESCRIPTION OF THE FIGURES

These features and aspects of the invention, as well as its advantages,are better understood by referring to the following description,appended claims, and accompanying drawings, in which:

FIG. 1 is a schematic overhead view of a noseroller for a conveyorassembly including offset bearings, according to an embodiment of theinvention;

FIG. 2 is a side view of a conveyor belt passing over two offsetbearings in a noseroller assembly of an embodiment of the invention;

FIG. 3 is an isometric view of a portion of a noseroller assemblyincluding offset bearings according to another embodiment of theinvention;

FIG. 4 shows the portion of a noseroller assembly of FIG. 3 with thebearings removed;

FIG. 5 is an isometric view of a bearing suitable for use with theroller assembly of FIGS. 3 and 4;

FIG. 6 is an isometric view of a first bearing module of the portion ofthe noseroller assembly of FIG. 3;

FIG. 7 is an isometric view of a second bearing module of the noserollerassembly of FIG. 3;

FIG. 8 is a side view of a conveyor belt passing over a noserollerassembly having offset bearings according to an embodiment of theinvention;

FIG. 9 is a side view of a conveyor belt module suitable for use with anoseroller assembly of an embodiment of the invention;

FIG. 10 is an isometric bottom view of the conveyor belt module of FIG.9;

FIG. 11 is a schematic bottom view of a conveyor belt formed of modulesshows in FIG. 9 passing over offset bearings;

FIG. 12 is a side view of the assembly of FIG. 11; and

FIG. 13 shows another embodiment of a conveyor belt module includingbottom recesses for accommodating bearings.

DETAILED DESCRIPTION OF THE INVENTION

A conveyor assembly employs offset bearings to facilitate transitioningof a conveyor belt around a noseroller or other element in a conveyor.The invention will be described below relative to certain illustrativeembodiments, though those skilled in the art will recognize that theinvention is not limited to the described embodiments.

FIG. 1 shows an embodiment of a noseroller assembly 10 having offsetbearings. The noseroller assembly 10 guides a conveyor belt at one endof a carryway to or from a returnway. The noseroller assembly 10includes a base portion 12 having an upper surface upon which a conveyorbelt rides and a curved front edge 14 marking the end of a carryway forthe conveyor belt. Bearings are mounted in the roller assembly 10 toreduce friction between the conveyor belt and noseroller base portion 12and facilitate operation of a conveyor belt. The illustrative noserollerassembly 10 includes at least two sets of bearings: a first set ofaligned bearings 20 and a second set of aligned bearings 30 offset from(unaligned with) the first set. The illustrative first set (forward set)comprises three bearings 20, mounted to the base portion 12 androtatable about axles 24. The first axles 24 align along first lateralaxis 22. The outer surfaces of the bearing 20 in the first set extendpast the edge 14 by a selected distance P.

The bearings 30 in the second set (rear set) are aligned along a secondlateral axis 32 forming the axis of rotation for the bearings 30. Theaxles 34 for the second bearings 30 align with the second lateral axis32. The second lateral axis 32 is spaced from the first lateral axis 22by a selected distance D. In the illustrative embodiment, the outermostsurfaces of the bearings 30 are recessed (inset) from the edge 14 by adistance I. The top surfaces of the bearings 20 and 30 are flush withthe upper surface of the base portion 12 to contact a conveyor beltriding over the noseroller assembly.

In the illustrative embodiment, the bearings are staggered, with thebearings 20 in the first set alternating with the bearings 30 in thesecond set. Alternatively, the bearings may have any suitable pattern,such as two aligned, adjacent first bearings 20 that protrude from theedge 14 then an unaligned, recessed second bearing 30, then two aligned,adjacent protruding first bearings 20, and so on.

The bearings 20 in the first set contact the bottom of a conveyor beltto transition the conveyor belt around the noseroller assembly 10.

The bearings 30 in the second set at the second location contact theconveyor belt before the transition point at edge 14 to reduce wear. Thesecond bearings 30 facilitate smooth operation of the conveyor belt andextend the lifetime of the belt by reducing wear. The second, recessedbearings 30 can be a different size than the protruding bearings 20 orthe same size.

FIG. 2 is a side schematic view of a conveyor belt 200 transitioningaround a noseroller assembly including unaligned bearings 20, 30. Theillustrative conveyor belt 200 is a modular plastic conveyor belt formedof a plurality of linked modules 210, but the invention is not solimited. As shown, a second bearing 30 is spaced inwards from a firstbearing 20. The second bearing 30 is used to prevent wear and the firstbearing 20 guides the conveyor belt around a noseroller substrate.

In one embodiment of the invention, a noseroller assembly may comprise aplurality of bearing-carrying modules stacked together. FIG. 3 shows aportion of a noseroller assembly including side-by-side bearing modules302, 304. A first module 302 comprises a base substrate 312 and openingsfor receiving a first bearing 320. The first bearing protrudes slightlyfrom the front edge of the module, forming part of a forward set ofbearings. The second module 304 includes openings for receiving a secondbearing 330. The second bearing 330 is recessed from the front edge ofthe modules and is offset from the first bearing 320 when the bearingmodules 302, 304 are adjacent to each other. Any number and combinationof bearing modules may be stacked together to form a noserollerassembly. Any suitable means can be used to couple the modules together.

FIG. 4 shows the noseroller assembly of FIG. 3 with the bearingsremoved. FIG. 5 shows an example of a bearing 320 suitable for use witheither of the modules 302, 304. FIG. 6 shows the first module 302 aloneand FIG. 7 shows the second module 304 alone. Multiple of the firstmodules 302 and second modules 304 can be coupled together in anysuitable pattern and number to form a noseroller for a conveyor.

The first module 302, which houses a bearing positioned to protrude fromthe front edge of the noseroller assembly to contact and guide aconveyor belt around the noseroller front edge, includes a top surface312. The top surface contacts a conveyor belt riding over thenoseroller. Sloping recesses 342, 343 extend forward from the topsurface 312 at the side edges of the module to provide clearance for aconveyor belt. A bearing slot 362 is formed in the upper surface 312,between the sloping recesses 342, 343, starting about halfway down thesloping recesses 342, 343 and extending to the front edge 313 of themodule 302. An axle slot 372 intersects the bearing slot 362. Theillustrative axle slot 372 is formed at the front ends of the slopingrecesses 342, 343 and extends from one side 315 of the module to thesecond side 316. The illustrative axle slot 372 extends at an angle(non-perpendicular) relative to the top surface 312 and forms roundedtips 382 at the top of the front edge 313. The rounded tips 382 aretransition surfaces. The side walls of the axle slot 372 extend past thefront edge 313 and above the rounded tips 382 to form rounded lips 383.

To assemble a first module 302, a simple bearing 320, comprising acentral hub 323 and axles 324 extend from the central hub 323, isinserted in the slots 362, 372. The axles 324 pass through the axle slot372 and are held in place by gravity. The central hub 373 of the bearingis held in the bearing slot 362 such that the forwardmost portion of thecentral hub 373 protrudes beyond and above the rounded lips 383. Aconveyor belt traveling over the module will contact the bearing surfacerather than the surfaces 384, 385 or 315. The first, protruding bearing320 is thus positioned to facilitate the transition about the end of thenoseroller assembly.

Referring to FIG. 7, the second module 304 is configured to prevent wearin the conveyor belt caused by contact with the noseroller assembly. Forthis reason, the second module 304 positions a bearing in a differentlocation than the first module 302. The second module 304 includes a topsurface 314, sloping recesses 344, 445 in the top surface 314, a bearingslot 364 and an axle slot 374. The axle slot 374 is substantiallyvertical, instead of angled, though the invention is not so limited. Thesloping recesses 344, 345 are shorter than the sloping recesses 342, 343of the first module 302, placing the bearing slots 364 closer to theback 329 of the module 304. Curved transition surfaces 384 between theaxle slot 374 and the front edge 315 of the module 304 are larger thanthe rounded tips 382 in the first module 302, because the axle slot 374is set farther back from the front edge 315 in the second module 304than the axle slot 372 in the first module 302. The second module 304also includes rounded lips 385 between the front of the bearing slot 364and the curved transition surfaces 384. The rounded lips 385 taper inthe front of the module.

As shown in FIG. 3, the modules 302, 304 are configured to placebearings so that bearing 320 protrudes slightly beyond the front edge ofthe assembly, while bearing 330 is slightly recessed and setback fromthe front edge. The bearing 330 contacts the underside of a conveyorbelt at a location 390, slightly above the top surface 314, to reducewear in the conveyor belt.

The bearing modules 302, 304 also include connection means forconnecting two or more modules together, in any suitable combination, toform a noseroller assembly. In the illustrative embodiment, each moduleincludes rod openings 392, 394 between the top surface and bottom of themodules and extending from one side of the module to the other. The rodopenings 392, 394 align with each other for form a rod-receivingpassageway. A connecting rod may be inserted the rod-receivingpassageway to connect two modules 302, 304 together in a particularorientation. Any suitable means for connecting two or more modulestogether may be used.

FIG. 8 shows a modular plastic conveyor belt 200 going over noserollerassembly comprising at least two modules (module 304 with recessedbearing shown) having unaligned bearings. The recessed bearing 330contacts the conveyor belt first, at location 390, lifting the beltslightly above the top surfaces 312, 314 to prevent or reduce wear.Then, the protruding bearing 320 at the nose of the noseroller assemblyguides the belt around the nose and into the returnway. The arrows showclearance between the noseroller substrate and the bottom of the belt200.

The bearings 320, 330 can be dropped into the respective slots and heldin place by the weight of the belt and-or gravity, or through anysuitable means.

The conveyor belt 200 may be configured to accommodate a noserollerassembly with unaligned bearings. FIGS. 9 and 10 show an embodiment of aconveyor belt module 210 suitable for use with a noseroller assemblywith offset bearings. The module includes a module body having a topconveying surface 211, a bottom surface 212 and hinge elements 213, 214for connecting the module to adjacent modules the conveyor belt. Thebottom surface 212 may be shaped to accommodate the bearings 320, 330 onthe noseroller assembly. The illustrative module 210 includes bearingpockets formed by recesses 212′ in the bottom surface 212. The recessesare defined by sidewalls 218 which form a track for receiving thebearing. The recesses are curved, though the rest of the bottom surface212 is flat.

FIGS. 11 and 12 schematically show a portion of a conveyor belt 200formed by modules 210 going over offset bearings 220, 230 in anoseroller assembly. The recesses 212′ in the bottom surface 212 of themodules receive the bearings 320 or 330 to facilitate transition of theconveyor belt 200 around the noseroller assembly.

FIG. 13 shows another embodiment of a conveyor belt module 400 includingat least one bearing pocket 414 in an otherwise flat bottom surface 412to accommodate a bearing in a noseroller assembly. The recess formingthe bearing pocket 414 is deeper than the recess 212′ and forms achannel 416 in the hinge element 419 for tracking a bearing.

The invention has been described relative to certain illustrativeembodiments, but the scope of protection is not limited to theseillustrative embodiments.

What is claimed is:
 1. A noseroller assembly for transitioning aconveyor belt at an end of a carryway, comprising: a substrate having arounded front edge; a first set of bearings rotatably mounted to thebase and aligned along a first axis; and a second set of bearingsrotatably mounted to the base and aligned along a second axis spacedfrom the first axis.
 2. The noseroller assembly of claim 1, wherein thebearings in the first set protrude beyond the rounded front edge.
 3. Thenoseroller assembly of claim 1, wherein the bearings in the second setare recessed from the rounded front edge.
 4. The noseroller assembly ofclaim 1, wherein bearings in the first set alternate with bearings inthe second set.
 5. The noseroller assembly of claim 1, wherein thesubstrate comprises a plurality of modules with bearing openings coupledtogether.
 6. The noseroller assembly of claim 1, wherein the substratehas an upper surface including openings for receiving the bearings. 7.The noseroller assembly of claim 6, wherein the upper surface includessloping recesses adjacent the openings.
 8. A noseroller assembly,comprising: a substrate having a rounded front edge; a first opening inthe substrate for rotatably mounting a bearing; and a first bearingmounted in the first opening such that the front surface of the firstbearing is recessed from the rounded front edge.
 9. The noserollerassembly of claim 8, further comprising: a second opening in thesubstrate; and a second bearing rotatably mounted in the second opening.10. The noseroller assembly of claim 9, wherein the second bearingprotrudes past the rounded front edge.
 11. The noseroller assembly ofclaim 8, wherein the substrate comprises a plurality modules coupledtogether, each module including an opening and a bearing mounted in theopening.
 12. A noseroller assembly for a conveyor belt, comprising: afirst bearing module having an upper surface, a first side edge, asecond side edge, a rounded front edge, a rear edge, a bottom and anopening in the upper surface for receiving a bearing; a first bearingmounted in the opening of the first bearing module; a second bearingmodule adjacent the first bearing module having an upper surface, afirst side edge adjacent the second side edge of the first bearingmodule, a second side edge, a rounded front edge, a rear edge, a bottomand an opening in the upper surface for receiving a bearing; a secondbearing mounted in the opening of the second module; and a connector forconnecting the first bearing module and the second bearing module sothat the rounded front edges align with each other.
 13. The noserollerassembly of claim 12, wherein the first bearing protrudes past therounded front edge of the first bearing module.
 14. The noserollerassembly of claim 13, wherein the second bearing is offset from thefirst bearing.
 15. The noseroller assembly of claim 13, wherein thesecond bearing is recessed from the rounded front edge.
 16. Thenoseroller assembly of claim 12, wherein the connector comprises a rodinserted in aligned rod-receiving openings formed between the uppersurfaces and bottoms of the first bearing module and the second bearingmodule.
 17. A conveyor belt module, comprising: a module body extendingfrom a top surface to a bottom surface, laterally from a first side edgeto a second side edge and longitudinally from a first end to a secondend; a plurality of spaced-apart hinge elements extending from the firstend and the second end; and a plurality of bearing pockets formed in thebottom surface for accommodating a noseroller assembly having bearings.